Structural member



May 7, 1968 F. A. THULIN, JR 393811,439

STRUCTURAL MEMBER Filed oct. 21, 1965 5 Sheets-Sheet 2 magg May 7, 1968 F. A. THULIN, JR

STRUCTURAL MEMBER 5 Sheets-Sheet 5 Filed 001,. 21. 1965 United States Patent O M 3,381,439 STRUCTURAL MEMBER Frederick A. Thulin, Jr., Mount lrospect, Ill., assignor to United States Gypsum Company, Chicago, IIL, a corporation of llllinois Filed Oct. 21, 1965, Ser. No. 499,939 1i) Claims. (Cl. 52-729) ABSTRACT GF THE DSCLOSURE A structural member includes parallel, spaced opposed flanges with a supporting web comprising a series of web sections extending the length of the member and having central portions joined to one another along the center of the member. Each web section includes first and second end portions, with alternate sections having their first end portions integral with one longitudinal edge of one flange and their second end portions integral with the corresponding edge of the other flange, and the remaining web sections having their end portions similarly extending to, and allixed to, the other longitudinal edges of the flanges. Each of the first end portions are coplanar with the second end portions of adjacent web sections, whereby the end portions of such adjacent sections form joined straight struts extending diagonally across and progressing longitudinally of the member.

This invention relates to structural members and particularly to beams, studs or trusses formed of sheet metal or like materials for use as components in constructing walls, ceilings, floors and roofs.

One particular use for this invention is in support members for interior building walls of wallboard construction. In such constructions, wallboard panels are often secured to metal studs by driving fasteners through the panels and into or through flange portions of the studs, for instance as disclosed in Nelsson etal. U.S. Patent No. 3,056,234. One stud currently in common use in such constructions is a channel-type sheet metal stud. The flexibility of this stud in torsion and the tendency of the flanges to bend under laterally applied loads present certain problems in the use of the studs. For instance, there is a tendency for the flanges to be deflected away from a wallboard panel when a workman attempts to drive fasteners through the flanges during attachment of wallboards in constructing partiions.

Recently, an improved sheet metal structural member has been proposed to overcome these problems, as disclosed in the copending application of Henry A. Balinski, Ser. No. 359,867, led Apr. l5, 1964. This improved mem Iber is provided with a pair of opposed flanges and a web structure comprising a series of web sections with alternating elements joined to opposite edges of each flange. The web sections extend between the opposite longitudinal edges of the flanges in alternating diagonal fashion whereby each adjacent pair of sections form an X as viewed from the end of the stud. The web sections thus support the flanges along their opposite edges, and the resulting structure has high torsional strength. Further, this member may be formed of a unitary sheet metal blank, with the web sections being formed from the central portion of the blank and the flanges being formed from the edge portions. Each web section remains integral with one longitudinal edge of a flange and is affixed to the opposite longitudinal edge of the opposing flange. In one form, all the web sections are integral with the respective flanges along one side of the stud and are all affixed to the flanges along the opposite side to facilitate fabrication.

3,381,439 Patented May 7, 1968 ICS The present invention is directed to further improvements in the abovenoted general type of structural meniber.

It will be appreciated that several aspects of structural support are important in structural members of the subject type. One of these aspects is torsional strength or rigidity of the individual members. This is particularly important during assembly to avoid torsional or twisting and retreating movement of each member as fasteners are forced against and through its flanges. A second important characteristic is stillness or resistance of the member to deflection under a load applied laterally of an assembled partition. Other aspects include bending of the flanges, impact resistance, compressive (columnar) strength, bending strength (failure load), etc. While the abovenoted crossbraced member is possessed of numerous advantages, including high torsional resistance, good support of the flanges, other satisfactory strength characterisiics, and economy in fabrication and assembly, it has been found to have relatively low resistance to deflection in assembled partitions.

It is an object of this invention to provide an improved structural member having high resistance to deflection and retaining the several advantages of the aforedescribed crossbraced member.

It is another object of this invention to provide an improved structural member fabricated of sheet metal.

It is a further object of this invention to provide a structural element having opposed parallel flanges and a supporting web structure providing support for both edges of the flanges, having high torsional strength and high resistance to deflection normal to the planes of the flanges, and which may be fabricated from a unitary blank of formable sheet material.

It is another object of this invention to provide an improved method of fabricating structural members of sheet metal.

It is another objects of this invention to provide structural members as set forth above Aand which may be economically produced.

Additional objects and advantages will become apparent to those skilled in the art from the description accompanying drawings and appended claims.

In carrying out this invention in one illustrative form, an elongated structural member is fabricated from a unitary sheet metal blank and provides high resistance to deflection as well as high torsional strength or rigidity. This members includes a pair of flanges supported in spaced opposed relation by a web extending longitudinally of the flanges. The web includes a series of web sections formed from the central portion of the sheet metal blank and is generally of X shape in projected end view. However, each of such sections, together with the joined flanges, is of the configuration of the capital Greek letter sigma, with the configuration being reversed in alternate sections to define such X shape. Said web sections include central portions substantially aligned with one another between the flanges. Alternate web sections in said series include first and second end portions extending from the central portions thereof, with the first end portions integral with one longitudinal edge of one of the flanges and the second end portions integral with the longitudinal edge of the other of said flanges at the same side of the structural member, The remaining web sections have rst end portions joined to the other longitudinal edge of said one of said flanges and second end portions joined to the other longitudinal edge of the other flange. Each of the first end portions is substantially coplanar with the second end portions of the web sections adjacent thereto in the series. The central portions of adjacent web sections are integral with one another in the area of intersection of the planes defined by the end portions of these web sections. Aligned ribs may be formed in adjacent coplanar end portions, each rib extending from the area of joining of adjacent web sections to the area of joining of the respective end portion with the respective flange.

For a more complete understanding of this invention, reference should now be had to the example illustrated in the drawings wherein:

FIG. l is a fragmentary perspective view of a partition construction including a stud embodying teachings of this invention;

FIG. 2 is a perspective view of a portion of a stud according to FIG. 1;

FIG. 3 is a plan view of a portion of a sheet metal blank cut to form a structural member such as the stud of FIG. 2r;

FIG. 4 is a side elevation view of the stud of FIG. 2;

FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 4 looking in the direction of the arrows;

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 4 `and looking in the direction of the arrows, and

FIG. 7 is a cross-sectional view taken along line '7 7 of FIG. 4 and looking in the direction of the arrows.

Referring now to the drawings and more particularly to FIG. 1, a stud is illustrated as being supported in a vertical position and having a wallboard panel 22 secured thereto by a plurality of fasteners 24. The fasteners may be rotary screw fasteners such as are disclosed in US. Patent No. 3,056,234, and which are driven through the panel and through the underlying iiange 26 of the stud.

As best seen in FIGS. 2, 4, 6 Iand 7, the stud 20 comprises a pair of spaced, opposed, generally parallel, elongated flanges 26 and 28 connected together by a web 30 extending longitudinally of the flanges. The web 30 comprises a series of web sections 32 and 34, in alternating arrangement. The central portion of each web section is integrally joined to the central portion of each web section adjacent thereto as at 36 and 38, approximately along the geometrical center line or median line of the stud 20. Each web section 32 is identical to each other web section 32, and each web section 34 is identical to each other web section 34.

Each web section 34 includes end portions 40 and 42 integrally joined to one -another at the center portion of the section. End portion 4()` is also integrally joined to an edge liange or lip portion 44 which is integral with the liange 26. The end portion 42 is also integral with a similar edge ange or lip portion 46 which is integral with the flange 28.

Each web section 32 includes end portions 48 and 50 integrally joined to one another at the center portion of the section. The distal end of end portion 48 is aflixed to an edge flange or lip portion 52 integral with the ange 26. The distal end of end portion 50` is joined to a similar edge iiange or lip porti'n 54 which is integral with liange 28. The joining of the end portions 48 and 5t) to edge lianges 52 and 54 may be effected by staking, as illustrated at 55 and 55a, spot welding, welding, riveting, interlocking can seams, or any other suitable means.

It will be observed, particularly with reference to FIGS. 2, 6 and 7, that the web sections 32 and 34 collectively provide a web construction of X shape in projected end view. However, each of the individual sections 32 and 34, together with the joined flanges 26 and 28, is of the configuration of the capital Greek letter Sigma (see web section 34 as viewed in FIG. 7), with the conguration being reversed in alternate sections (see web section 32 yas viewed in FIG. 6). rI`he center portions of these sigma and reversed sigma sections are aligned along the median or center line of the stud 2t) and are integrally joined along this line at 36 and 38 as aforenoted. Further, the end portion 4() of each web section 34 is coplanar with the opposite end portions 50 of the two adjacent web sections 32 joined thereto. Similarly, the end portion 48 of each web section 32 is coplanar with the opposite end portions 42 of the adjacent web sections 34 joined thereto.

The end portions 4t), 42, 42B and 5t) are formed with elongated reinforcing ribs 56a, 56.12, 56C and 56d as illustratcd. The segment of each end portion in which such a reinforcing rib is located is straight and continuous from the respective integral joint 36 or 33 to the distal end of the respective end portion, at or near a common point of attachment to the respective liange as at 55a. Each such segment is aligned with a similar segment in a coplanar end portion of an adjacent web section; note the longitudinal alignment of ribs 56a and 56C with ribs 56d and 56b as best seen in FIGS. 1, 4 and 5. Further, the segments of each such aligned pair are integrally joined through the respective integral intervening joint 36 or 38. Thereby, Stich aligned segments of the end portions and the intervening joint areas form straight and continuous support strut elements from one edge of one liange diagonally across the stud 20 to the opposite edge of the opposing flange, as shown in FIG. 5. These straight diagonal portions apparently serve `as strut elements for transferring tensile and compressive loads between the opposing flanges 26 and 28. The ribs 56a, 5612, 56C and 56d serve as reinforcements in these segments.

It will be appreciated that vas a load is applied to one flange 26 or 28, laterally of the stud 20, a tensile force will be generated in one of the aligned support strut elements including each integral joint 36 and 38, with a compressive force in the other support strut element including each of these integral joints. |Thus the load bearing strut elements support one another in the areas of intersection at 36 and 38. The design of the web is symmetrical to provide for equal strength and stiffness against deflection under loads applied in either direction, laterally of the stud.

In the illustrated stud 20 the angle between each of the aligned support strut elements and the planes of the litanges, or the median line of the stud, is about 45. The optimum value for this angle to obtain a high degree of stiffness will vary somewhat from 45, depending upon various design factors, such as the particular material and the thickness of the web structure. It will be appreciated that the angle be'tween the support strut elements and the flanges can 'be varied by varying the Width or spatcing of the web sections (measured longitudinally of the stud), in relation -to the depth of the stud, i.e., the distance between the flanges. The dimensions of a required structural member and production considerations may aiect the desired width or spacing of the web sections and thus 'affect the angle between the strut elements and the tianges. However, this angle should be between about 25 and about 75.

Each flange 26 and 28 and the respective lip portions 44, 46, 52 and 54 form a channel-shaped member. The lip portions are preferably bent inward of planes normal to the respective ange, to lie in or parallel and adjacent tto the planes assumed by the end portion's of the web sections in the completed stud, as shown in FIGS. 6 and 7. Thereby the'se lip portions are in alignment with the aforementioned support strut elements to enhance the bralcing etfect of the -web sections.

The web sections may be formed with suitable openings in their central areas to form passages for services, such as the conduit 60 shown in FIG. 1. In the illustrated embodiment a circular service opening 62 is provided in each of the web sections 32.

The illustrated stud 20 may be formed of a unita-ry blank of sheet metal. This is perhaps best illustrated by reference to the unitary blank 20a, shown in FIG. 3. Elements 48a and 50a for forming end portions 48 and 50 are eut or struck from the central web portion 30a. Cutout areas may be removed as at 64 and 66to facilitate deforming the blank to the desired configuration of the stud. The intervening portions of the blank at 40a and 42a, between 4the areas from which the portions 48a and 50a are struck, form the end portions 40 and 42, respectively. The openings 62 may be cut or stamped in the web sec-tions and the ribs 56a, 5611, 56C and 56d may be formed by pressing or rolling grooves in one side of the blank 20a at the same time as end portions 48 and 50 are formed. Thereafter the blank 20a is bent or folded `along appropriate lines to form the longitudinal edge portions 68 and 70 into the respective flanges 26 and 28 and the integral lip portions 44, 46,52 and 54. At a suitable time in the forming operationthe cen'ter integral portion of the web 30a is formed inwardly along its center line `to a point midway `between the opposing flanges, i.e., to a -line approximating the median or geometrical center l-ine of the stud. Simultaneously, or in a separate folding step, the end portion-s 48a and 50a are bent into engagement with the edge flanges 44 and 46 and are joined to these flanges by any suitable securing means.

Studs con-structed as in the illustrated embodiment of this invention have demonstrated resistance to deflection about 2.5 times greater than the resistance -of channel studs and twice the resistance of the prior cross-braced studs of the same dimensions and formed of sheet metal of the same gauge. With panels secured to the studs, as in partition construct-ions, the present stud demonstrated resistance to deflection abou-t 10% greater th'an the channel stud and about double that of the prior crossbraced stud. At the same time the present studs have provided substantially the same bending load (failure) strength as the prior cross-braced studs and the improved torsional resistance and flange bending resistance of these studs. Further, studs in accordance with the present inven'lion c'an be conveniently and economically forme-d from unitary blanks of sheet material as indicated above.

`It will thus be seen -that an improved structural member has been provided which has greatly improved resistarfce to deflection while retaining the beneficial features of strength and facility of fabrication provided by the noted prior crossbraced structural member. The present improve-d web construction provides support for both edges of the flanges and pro-vides high torsion-al strength While obtaining high resistance -to deflection. These several advantageous results are obtained in a structure which may be conveniently and economically fabricated from a unitary blank of formable sheet material such as sheet metal. Further, a relatively simple and improved method of fabrication has been disclosed for forming such structural members.-

While a particular embodiment of the invention has been shown, it will be understood, of course, that the invention is not limited thereto since many modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Therefore, it is contemplated by the appended claims to cover any such modifications as fall within the true spirit and scope of the invention.

I claim:

1. An elongated structural member comprising a pair of elongated flanges, and a web comprising a series of web sections extending longitudinally of said flanges and supporting `said flanges in parallel, spaced, opposed relation, said series including a first web section extending between said flanges and having a first end portion joined to one longitudinal edge of one of said flanges and a second end portion joined to the corresponding edge portion of the other of said flanges, and a second web section adjacent said first section and extending between said flanges and having a first end portion joined to the other longitudinal edge of said one of said flanges and a second end portion joined to the other longitudinal edge of said other flange, said first end portion of each of said first and second sections being substantially coplanar with said second end portion of the other of said sections, and said first and second sections being joined together in the area of intersection of the planes defined by said end portions, whereby such coplanar adjacent end portions define strut sections extending generally longitudinally of and diagonally across said member.

2. An elongated structural member las in claim 1 wherein each of said end portions includes a straight, continuous segment extending from the edge of the flange with which such end portion is joined to the arca of joining of said web sections with one another.

3. An elongated structural member as in claim 2 wherein said segment in each of said first end portions is longitudinally aligned with said segment in la second end portion coplanar therewith, whereby each such pair of aligned segments forms a straight support element extending diagonally across said structural member from one edge of one of said flanges to the opposite edge of the other of said flanges.

4. An elongated structural mem-ber fas in Iclaim 3 wherein each of said segments is formed with a rein forcing rib, such ribs in aligned segments being 1ongitudinally aligned with one another.

S. An elongated structural member as in claim 3 wherein each of said end portions is secured to the re spective flange at the respective end of each of said segrnents therein.

6. An elongated structural member 'as in claim 1 wherein said member is formed of a unitary blank of sheet metal, each of said end portions of said first web section being integral with the respective flange to which it is joined, and said first and said second web sections being integral with one another in said area of intersection.

7. An elongated structural member as in claim 1 wherein said web is formed of sheet material and each of said end portions is a segment of said sheet material.

3. An elongated structural member comprising a pair of elongated flanges supported in spaced opposed relation by a series of web sections extending substantially the full length of said member, said web sections having central portions substantially aligned with one another between said flanges, each web section including first and second end portions extending from the central portion thereof, alternate web sections in said series having their first end portions joined to one longitudinal edge of one of said flanges and their second end portions joined to the corresponding longitudinal edge of the other of said flanges, the remaining web sections in said series having their first end portions joined to the other longitudinal edge of said one of said flanges and their second end portions joined to the other longitudinal edge of said other flange, each of said first end portions being substantially coplanar with said second end portions of the web sections adjacent thereto in said series, the central portions of adjacent web sections in said series being joined to one another in the area of intersection of the planes defined by said end portions.

9. An elongated structural member formed from a blank of deformable sheet material comprising a pair of penetrable channel-shaped flanges formed from parallel spaced portions of such blank and supported in parallel spaced and opposing relation -by a web portion formed from the portion of such blank lying between said flange portions, said flanges including opposed first edge lip portions and opposed second edge lip portions, said web portion being formed into a series of bi-planar bracing sections, each of said bracing sections being integrally joined to adjacent bracing sections in said series along the median line of said web portion, each of said biplanar sections including two end portions extending laterally of said median line, each alternate section in said series having one end portion thereof affixed to said first lip portion of one of said flanges and the other end portion thereof affixed to said first lip portion ofwthe other of said flanges, each of the remaining sections in said series having one end portion thereof integral with said second lip portion of said one of said flanges and the other end portion thereof integral with said second lip portion of the other of said anges, said anges and successive bracing sections being substantially of the configuration of a sigma and `a reverse sigma as viewed from an end of the structural member.

10, An elongated structural member as in claim 9 wherein said rst lip portion of said one of said anges and said end portions affixed thereto and said second lip portion of said other of said flanges and said end portions integral therewith are substantially coplanar, and said second lip portion of said one of said anges and said end portions integral therewith and said rst lip portion of said other of said anges and said end portions affixed thereto are substantially coplanar.

References Cited UNITED STATES PATENTS '7/1925 Schenck 52-729 10/1963 Ellis 52-557 5/1939 Geib 52--732 11/1965 Slowinski et al. 52-729 XR 6/ 1966 Tersigni 52-729 XR FOREIGN PATENTS 7/1897 Germany.

BOBBY R. GAY, Primary Examiner. ANDREW M. CALVERT, Assistant Examiner. 

